Exhaust Studs.

[Will Wallace]

Just pulled the downpipe off the Td5. Seems the flex joint has a 200k life, as I had to change one at the same time in my 110.

Anyways, I could sometimes hear a scream or whistle. I hoped it was the flex joint.

Seems I have 1 snapped stud. It is the top foremost one. (cyl 1?)

Can I purchase just one of these or do I need to do the bloody lot?

I'm in Sydney but head back to Townsville in 3 weeks. I'm tempted to leave it be till I get home, as cash is tight. If I can do just the one then I will.

Part #? And do I have to buy genuine or can I get the stud from an auto supplier?

Will.

[IanP]

Hi Will,

You have to take the manifold off so I would suggest you do them all. They are not expensive and although many say to use high tensile studs, I would rather have a stud break (easily replaceable) than strip the thread it goes into.

If the broken stud has broken below the surface, the studs are relatively soft and can easily be centre popped, drilled and removed with an Ezi Out.

Ian

[Will Wallace]

Don't suppose you would know the size? Thread? Supplier? Part #?

Will.

[IanP]

Will, they are M8 by 38mm long, they were cheap and I got them from Rovacraft in Melbourne. I cannot recall the cost, but any LR dealer or LR specialist should have them. I used bell washers with them to allow a small amount of 'give', but it is not essential to do that.

Seeing you snapped one stud I would replace them all otherwise you may be taking the manifold off again in six months time! :o

Ian

[Scouse]

You could well find the manifold warped too. It's a common problem & there are numerous ways to fix it detailed on AULRO.

[Will Wallace]

How does one remove snapped exhaust manifold studs on a td5?
What tools, technique?

Have already removed the manifold and have 3 broken.

If anyone is near Liverpool or Moorebank NSW that has done this, some help would be appreciated.

Will.

[Will Wallace]

Cheers scouse.

I previously had a 110 td5, so am well aware of the issues of the mighty little engine. Hahaha

I have limited phone internet so searching is also limited.

Will.

[Scouse]

Grind webbing & enlarge holes:
http://www.aulro.com/afvb/discovery-2/177130-td5-exhaust-manifold-gaskets.html

Webbing & stainless studs:
http://www.aulro.com/afvb/discovery-2/173666-discovery-2-small-whistle.html

Bigger studs:
http://www.aulro.com/afvb/discovery-2/161593-why-doesnt-td5-have-support-arm-manifold.html

Webbing 'how to' & stud kit info:
http://www.aulro.com/afvb/discovery-2/160646-td5-stainless-steel-exhaust-manifold-studs.html

Webbing 'how to':
http://www.aulro.com/afvb/discovery-2/144933-td5-exhaust-manifold-grinding-out-web.html

More here:
http://www.aulro.com/afvb/discovery-2/128857-old-warped-exhaust-manifold-td5.html

http://www.aulro.com/afvb/discovery-2/136844-td5-exhaust-stud.html

http://www.aulro.com/afvb/discovery-2/118547-replacement-exhaust-manifold-td5.html

http://www.aulro.com/afvb/discovery-2/50112-broken-manifold-studs-again.html

Happy reading :).

[Will Wallace]

Thanks a great deal for the time you took to find all that Scouse.

Greatly appreciated.

Will.

[G Griggs]

I removed a broken stud last weekend. It was a rear stud though and i had good access. I left the manifold on and used a drill bit the same size as the manifold to centre the drill bit and leave a dimple for the drill bit (it had broken on an angle so centre punching and drilling would have been hard)
Then i ran a 4mm drill bit down the centre of the stud. when it went to break through it gripped the stud and wound it to the bottom of the hole. That was good because it meant the stud wasn't jammed in. When I went to wind the stud out the start of the thread was damaged, so screwed it back in and ran a tap down the hole and cleaned it up. The stud then came out easily.

[IanP]

If it is below the surface, center pop the stud, use a small diameter drill and then an easy out. I used plenty of WD40 prior to doing this and the broken studs came out easily.

If there is still some stud showing, you can use anything to grip it or use a stud remover. I used a stud remover and they grip the stud with a set of rollers - very easy removal. There are a number of different types but the type I used are like a set of sockets such as Stud Remover SET 4pc Suit 6 8 10 12mm Studs Hduty | eBay (http://www.ebay.com.au/itm/STUD-REMOVER-SET-4PC-SUIT-6-8-10-12mm-STUDS-HDUTY-/301004588950)

Ian

[Will Wallace]

Thank you Ian. After alp the doom.and gloom I had read about easy outs, I just did it and would be able to do it bind folded next time. Thanks for all the help. It was invaluable.
Thanks again.

Will.

[Will Wallace]

Thanks all.

As on my other post regarding this, I couldn't thank you enough.

I always feel pretty handy with the tools but this one had me nervous,as I have tight funds and have to be off on a small trip in the next week.

Only had a bit of trouble on one of the 3 studs. However I think that might have been due to drilling it and then trying to remove it straight away. I let it cool and out it came.

Could do it with eyes closed now.

Thanks again folks, AULRO = $saved.

Will.